Method and apparatus for feeding and advancing popcorn bags from a stack

ABSTRACT

The present invention relates to a simplified mechanism for feeding and advancing popcorn bags or other receptacles for use in food or consumable filling applications, such as microwave popcorn to downstream processing stations. More specifically, the present invention includes the provision of a vacuum to draw a bag into operative association with a moving belt in order to advance the bags from a stack or supply.

CROSS-REFERENCES TO RELATED APPLICATIONS

[0001] None.

BACKGROUND OF THE INVENTION

[0002] The present invention relates to a simplified mechanism for feeding and advancing popcorn bags or other receptacles for use in food or consumable filling applications, such as microwave popcorn, to downstream processing stations. More specifically, the present invention includes the provision of a vacuum to draw a bag into operative association with a moving belt in order to advance the bags from a stack or supply.

[0003] Currently, a number of complicated and expensive feeder devices are used to move popcorn bags from a magazine or supply hopper to the filling, folding and other processing stations. Typically, such devices use mechanical arms, pickers, suction cups and other associated equipment to affect the transfer of the bag from the supply to the filling and processing stations. However, difficulties may arise in the timing of the movement of such mechanical arms or picks such that the cycling of the apparatus can become offset from the speed requirements of the filling or processing operations. In addition to the movement of the mechanical arms, the suction cups may not adequately grasp the bag from the stack causing the filling or folding apparatus to miss a sequence. This can cause product that was intended to be delivered into a bag to be inadvertently dumped or dropped on the filling apparatus or on the floor.

[0004] Such complex mechanical devices may suffer from a very simple problem and inadvertently remove more than one bag at a time from the stack due to bags clinging together because of static forces, or sticking due to exposed adhesive or ink that did not set or dry prior to putting the bags into a stack. In addition, with the many moving parts of such a system, more maintenance and sequencing of the equipment is usually required.

[0005] In addition to the problem associated with picker arms, the magazine which supplies the stack of popcorn bags may not sufficiently advance the supply of bags so that the picker arm reaches the bag, again causing timing delays and other problems identified above due to missed sequencing of the picker arms and bag supply. When a bag is not delivered to the necessary location, spillage can occur and this not only causes waste of the product but also delay in having to stop to clean up the spill. In addition, popcorn kernels or oil which are typically used in filling the bags can contaminate the apparatus causing additional mechanical problems or difficulties. Examples of such prior art systems are illustrated in U.S. Pat. No. 5,480,372, 5,463,845 and 5,507,132.

[0006] Another prior art solution is described in U.S. Pat. No. 5,020,688, which describes a vending machine in which popped popcorn is dispensed in bags. Here, a predetermined charge of the unpopped popcorn is placed in a bag and then the filled bags are placed in a stack. A plunger is used to knock the bags from the stack into the cooking area. Unfilled bags would not have sufficient rigidity to withstand the impact or pushing forces associated with a plunger device and as such, would likely not advance the bags to the processing line.

[0007] What is needed therefore is a simplified, efficient and reliable system for delivering a supply of unfilled popcorn bags to a filling process that overcomes the foregoing problems.

[0008] Publications, patents and patent applications are referred to throughout this disclosure. All references cited herein are hereby incorporated by reference.

BRIEF SUMMARY OF THE INVENTION

[0009] The invention is now illustrated by reference to the following embodiments which are not intended to be limiting in scope but only to be representative of the invention.

[0010] A bag feeding device is described and includes a supply of bags that are supported and held in position by a stop. At least a first belt is provided and disposed adjacent to the supply of bags. The belt is capable of moving in order to advance at least one bag from the supply. There is at least a first vacuum source applied to the supply of bags to move at least one bag from the bag supply to a first position. An indicator or sensor is also provided to determine the position of the bag. In operation, the vacuum source moves at least one bag into operative association with the first belt and the indicator or sensor detects whether the one bag that has been moved from the supply in to the first position.

[0011] A further embodiment of the present invention describes a method of advancing a bag for a food processing line that includes the steps of initially providing a supply of bags for use in the processing line. The supply of bags is held in position by a stop. The bag is moved from the supply by the activation of a vacuum that pulls a bag from the supply. Next, the bag is advanced from the supply to a first position. The bag is sensed in the first position. A belt is used to move the bag from the first position to a second position. The bag is sensed in the second position to determine if the bag has been supplied to the processing line.

[0012] In a still further embodiment of the present invention a system for supplying popcorn bags to a processing line is described and comprises, a supply of popcorn bags held in position by a stop. A first belt disposed adjacent the supply of popcorn bags the first belt is moveable in a first direction to move bags from the supply. A second belt is disposed adjacent the supply of popcorn bags, the second belt is moveable in the same or first direction as the first belt, and the second belt is positioned in front of the first belt. A first vacuum source is disposed beneath the second belt and is adjacent a leading edge of the supply of popcorn bags. A second vacuum source is disposed beneath the second belt and is positioned in front of the first vacuum source. The first and second belts in cooperation with the first and second vacuum sources moves a bag from the supply of popcorn bags from a first position partially within an area covered by the supply of popcorn bags to a second position outside the area covered by the supply of popcorn bags so as to be able to pass the bag to the processing line.

[0013] The foregoing and other objects of the invention will become clear from an inspection of the detailed description of the invention and from the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] These, as well as other objects and advantages of this invention, will be more completely understood and appreciated by referring to the following more detailed description of the presently preferred exemplary embodiments of the invention in conjunction with the accompanying drawings, of which:

[0015]FIG. 1 depicts a side view of the bag feeder;

[0016]FIG. 2 depicts a side view of the bag feeder illustrating the advancement of a bag from the stack or supply;

[0017]FIG. 3 illustrates a side view of the apparatus showing the further advancement of the bag from the stack or supply;

[0018]FIG. 4 provides a depiction of the underside of the apparatus showing the perforated belts; and

[0019]FIG. 5 represents a flow chart of the operation of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0020] The present invention is directed to a feeding mechanism for supplying popcorn bags to a filling or feeding location. The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present invention. For example, while the popcorn bags of the present invention are suitable for use with microwave popcorn products, the invention is not to be so limited and the invention could be used with other bag filling operations such as in the supply of bags for a ready to eat meals, food and snack products, toiletries and cosmetics and the like.

[0021] Turning now to FIG. 1, the feeding apparatus is generally depicted at 10 and includes a stack or supply 12 of popcorn bags. The bag supply 12 has an adjustable bag stop 14 to hold the supply 12 of popcorn bags in position. Generally, the supply 12 is gravity fed, but a spring loaded feeder may also be used. In addition, the supply 12 may have a weighted cover placed on the top of the stack in order to bias the stack into position. The supply 12 may also be provided with walls, fingers or other guides to hold the stack of bags in position. The supply 12 has a leading edge and a trailing edge with the leading edge being in the direction the bags will travel after leaving the stack and the trailing edge being rearwardly thereof or on the edge of the supply opposite the leading edge.

[0022] Facilitating the egress of the popcorn bags from the supply 12 are a pair of upper and lower guides 16 and 18 which are spaced sufficiently apart to permit only the width of one bag to pass through the opening between guides 16 and 18. The width of the opening between the guides 16 and 18 can be adjusted as needed to accommodate different sizes of bags or articles to be supplied. For example, if the particular filling application requires two or more bags to be dispensed at any given time, the gap can be adjusted to permit the additional thickness to pass through. In the alternative, the present invention can be used to accommodate bags of different widths, such as popcorn bags intended to be a “single serving” size or a “family” size bag. In addition, one or both of the guides 16 and 18 may also be supplied with resilient guides or assists such as brushes, rubberized blades, felt pieces or the like to prevent more than the intended supply of bags to be supplied. The guides as well as the resilient assists overcome one of the problems identified above in that the guides prevent the dispensing of more than one bag at a time. In addition, the assists reduce static forces in the bags and can assist in identifying bags that are stuck together by other than static forces.

[0023] The combination of the guides 16 and 18 as well as the resilient assists and the stop 14 serve to keep the remaining portion of the supply of bags 12 from moving when the apparatus has been actuated to advance a bag from the supply 12.

[0024] Individual bags are dispensed from the supply 12 via suction created by vacuum sources at 20 and 22. At least one of the vacuum sources 20 and 22 is disposed beneath a belt 26. The belt 26 is provided so as to be adjacent the supply 12 of bags but is disposed at least partially beneath the bag supply 12. The belt 26 is driven in a clockwise manner through the use of one or more driven wheels 24 and 32. The drive mechanism (not shown) may consist of a typical electric motor connected to one or both of the wheels 24 and 32 or the motive power may be provided or supplied through a connection to the feeding/filling line so as to allow for proper sequencing. The belt 26 is operatively engaged with at least the leading edge of the supply 12 of popcorn bags, and the leading edge of the belt 26 is located prior to the upper and lower guides 16 and 18. A vacuum is created in each of the vacuum sources 20 and 22 through hoses 28 and 30.

[0025] The first vacuum source 20, as shown in FIG. 1, has a length that is approximately 1.5 to 2.5 times as long as the length of the second vacuum source 22. By providing an increased length, the first vacuum source 20 is able to grasp the bag from the supply 12 and move the bag from the first position to the second position (40 and 42 as shown in FIGS. 2 and 3). The second vacuum source 22 is provided adjacent an edge of the bag supply 12, that is the leading edge of the supply 12 or the direction in which the bags move from the supply 12 in the direction of the processing line. Vacuum 22 is position in this area so as to make a leading edge of a bag available for grasping by the combination of the belt 26 and the vacuum 22 in order to move the bag to a first position 40 as shown in FIG. 2.

[0026] A second drive means includes a belt 36, which is moved via wheels 34 and 38. The second drive means may be driven via a motor (not shown), or the wheels may be idler type rollers and are only activated due to the movement of the first drive belt 26. The second drive belt 36 is disposed rearwardly from the first drive belt 26. While as depicted in FIG. 1, the first belt 26 and the second belt 36 are disposed beneath or on the underside of the bag supply or stack 12, it is to be understood that in certain applications the first and second belts 26 and 36 could be disposed on the side or top of the supply 12, depending on the particular feeding configuration that is required. In addition, it should also be understood that the first and second belt 26 and 36 could be disposed on different surfaces of the supply 12, for example one belt on the bottom and one on the side of the supply 12.

[0027] Turning now to FIG. 2, one bag 40 from the supply 12 is engaged by the vacuum source 22. This vacuum source 22, pulls the bag from the bottom of the supply 12 to operatively engage the bag with belts 36 and 26. By operative engagement, the bag rests on the surface of the belts 26 and 36 and is held in position by the vacuum from one or more of the sources 20 and 22 until the bag is released. The vacuum created at source 22 reaches the bag surface through the use of perforations, holes, slots or other openings in the belts 26 and 36 as seen in FIG. 4. The vacuum pulls the bag 40 into a first position, which is distinct from the starting position at the bottom of the supply 12.

[0028] The bag 40 is now advanced to its first position either singularly through the operative use of belt 26 or cooperatively between belts 36 and 26, which is the preferable embodiment. The first position 40 of the bag, and as is illustrated in FIG. 2 is still within the area covered by the bag supply 12. That is, the bag while advancing from the first position to the second position moves from underneath the supply 12 of bags to outside the area of the supply of bags 12 so as to be completely free of the supply 12. Both belts 26 and 36 move in a clockwise direction in order to advance the bag 40. Belt 36 may or may not have perforations. In the event that belts 26 and 36 are separated from one another as shown in FIG. 2, a bridge 35 may be provided to prevent the bag 40 from drooping and being crumpled by the movement of the belts.

[0029] Referring now to FIG. 3, the vacuum source 22 has released the suction and the vacuum source 20 is engaging the bag 42 through perforated belt 26 to advance the bag from the first position shown in FIG. 2 (bag illustrated at numeral 40) to the second position (bag illustrated as numeral 42). In the second position at 42, the bag is capable of being grasped by an additional conveyor assembly or inserted into a carrier, car or shuttle (not shown) and then delivered to the first sequence in the filling or processing apparatus. The bag in its second position 42 is now out of the area covered by the supply 12 so that it can easily be passed to the processing line.

[0030] Turning to FIG. 4, an illustration of belts 26 and 36 is provided and includes a depiction of the perforation of the belts to enable the vacuum from sources 20 and 22 to reach the bags and hold the bags in operative association with one or more of the belts. While belt 36 is shown having a solid configuration it may also have a perforated surface to permit the vacuum to reach the bag supply or to reduce surface or static cling to the belt 36. In addition, the vacuum sources 20 and 22 are shown as separate or individual units. It is of course understood that the vacuum sources 20 and 22 may be single, continuous units running the width of the belts 26 and 36. In addition, FIG. 4 also further shows that vacuum source 20 is longer than source 22 (length illustrated as 21 in FIG. 1) so as to be able to advance the bag from the first position 40 to the second position 42 as illustrated in FIGS. 2 and 3.

[0031]FIG. 4 also provides a suggested placement for photoeyes, photosensors, solenoids, actuators or the like at 44 and 46. The placement of the photosensors should be such that the sensors can detect whether there are bags in the supply 12, such as with the position of eye 46 and the movement of the bag from the first position 40 to the second position 42 as is shown by the position of sensor 44.

[0032]FIG. 5 provides a flow chart illustrating operation of the present invention. The present invention is operated by a closed loop system detecting the presence or absence of a bag in the appropriate position. The system, through use of a sensor or other monitoring device, such as a inspection camera, mechanical actuator or the like, determines whether there is a bag in the supply 12 shown at step 100. If there is no bag in the supply, an error signal is generated 110, which indicates to the operator that the supply is currently empty. If the signal generated indicates that bags are in the supply 12, then the system at step 120 actives one or more of the vacuum sources 20 and 22 and the bag is pulled from the bottom of the stack 12 and advanced to the first position 40 as shown in step 130.

[0033] The apparatus/system 10 then detects whether the bag 40 is in the first position at step 140. If the bag has not reached the first position, the vacuum source 22 is activated and the system again attempts to pull and advance the bag to the first position 40. If the bag is in the first position 40, then vacuum source 20 is activated at step 150 and the other vacuum source 22 is temporarily turned off. Along with activation of vacuum source 20, belt 26 is rotated in a clockwise movement to advance the bag to the second position 42, as shown in FIG. 3 and depicted at step 160 in FIG. 5. If the bag is found to be in the second position 42, step 170, the vacuum 20 is turned off and the bag is advanced to the filling machine at step 180 and the system 10 is restarted to move the next bag from the supply 12 into position. If the bag is not detected at the second position, then the belt 26 is again restarted with the vacuum source 20 pulling the bag into operative association with the belt 26. If the bag does not reach the second position 42 after one or more tries an alarm sounds indicating a jam or supply empty situation.

[0034] In operation of the device, the apparatus 10 can run at about sixty cycles per minute, and in one example, twelve inch long bags were used. The speed of the device can be manipulated depending on the requirements of the filling station or the size or dimensions of the bag. While popcorn bags used in the present invention are generally quadrate in configuration, other geometric shapes may be supplied by using this invention. The adjustment needed to accommodate other bags may simply be one of adding additional guides to support the particular configuration or material to be handled.

[0035] It will thus be seen according to the present invention a highly advantageous bag feeding device has been provided. While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiment, that many modifications and equivalent arrangements may be made thereof within the scope of the invention, which scope is to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products. 

1. A bag feeding device, comprising; a supply of bags being supported by a stop; at least a first belt, disposed adjacent said supply of bags, said first belt capable of moving to advance at least one bag from said supply of bags; at least a first vacuum source applied to said supply of bags to move said at least one bag from said bag supply to a first position; an indicator; and wherein said at least one vacuum source moves at least said one bag into operative association with said first belt and said indicator detects whether said at least one bag is in said first position.
 2. A bag feeding device as recited in claim 1, wherein a second vacuum source is provided and applied to said at least one bag to move said at least one bag from said first position to a second position distinct from said first position.
 3. A bag feeding device as recited in claim 1, wherein said stop has at least first and second guides to control said supply of bags.
 4. A bag feeding device as recited in claim 3, wherein at least one of said first and second guides has resilient assists.
 5. A bag feeding device as recited in claim 1, wherein said feeding device is provided with a second belt at a position distinct from said first belt and disposed adjacent said supply of bags.
 6. A bag feeding device as recited in claim 1, wherein said first belt is disposed beneath said supply of bags.
 7. A bag feeding device as recited in claim 5, wherein said second belt is disposed beneath said supply of bags.
 8. A bag feeding device as recited in claim 5, wherein said position of said second belt is rearwardly disposed of said first belt.
 9. A bag feeding device as recited in claim 1, wherein said first belt is perforated.
 10. A bag feeding device as recited in claim 1, wherein said bag is intended for use with popcorn.
 11. A bag feeding device as recited in claim 10, wherein said bag is used for microwave popcorn.
 12. A bag feeding device as recited in claim 1, wherein said feeding devices is operated as a closed loop system.
 13. A bag feeding device as recited in claim 2, wherein said first and second vacuum sources apply a vacuum to said at least one bag through said first belt.
 14. A method of advancing a bag for a food processing line, comprising the steps of; providing a supply of bags, said supply of bags held in position by a stop; activating a vacuum to pull a bag from said supply; advancing said bag from said supply to a first position; sensing said bag in said first position; rotating a belt to move said bag from said first position to a second position distinct from said first position; and sensing said bag in said second position to determine if said bag has been supplied to the processing line.
 15. A method of advancing a bag for a food processing line as recited in claim 14 including a further step of applying a second vacuum to hold said bag to a belt after said bag has reached said first position.
 16. A method of advancing a bag for a food processing line as recited in claim 14, wherein the step of advancing said bag to said first position is done by use of a belt.
 17. A method of advancing a bag for a food processing line as recited in claim 14, wherein advancing of said bag from said first position to said second position is done by using first and second belts.
 18. A method of advancing a bag for a food processing line as recited in claim 14, wherein said bag is a microwave popcorn bag.
 19. A method of advancing a bag for a food processing line as recited in claim 14, wherein said belt is perforated to permit the vacuum to reach said bag.
 20. A method of advancing a bag for a food processing line as recited in claim 14, wherein said method is operated in a closed loop system.
 21. A system for supplying popcorn bags to a processing line, comprising; a supply of popcorn bags held in position by a stop; a first belt disposed adjacent said supply of popcorn bags, said first belt moveable in a first direction; a second belt disposed adjacent said supply of popcorn bags, said second belt moveable in said first direction, and said second belt positioned in front of said first belt; a first vacuum source disposed beneath said second belt and adjacent a leading edge of said supply of popcorn bags; a second vacuum source disposed beneath said second belt and positioned in front of said first vacuum source; and wherein said first and second belts in cooperation with said first and second vacuum sources move a bag from said supply of popcorn bags from a first position partially within an area covered by said supply of popcorn bags to a second position outside said area covered by said supply of popcorn bags so as to be able to pass said bag to the processing line. 